Confidential | Copyright © VAPCO Engineers Pvt. Ltd. Building Energy Efficient Technology VAPCO ENGINEERS PVT. LTD. WELCOMES ALL DELEGATES OF ALL INDIA DISTILLE‘YS ASSOCIATION Feb 18 th , 2016
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Building Energy Efficient Technology
VAPCO ENGINEERS PVT. LTD.
WELCOMES
ALL DELEGATES OF
ALL INDIA DISTILLE‘YS ASSOCIATION
Feb 18th, 2016
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
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VAPCO in a snapshot
• Provide sustainable & greener solutions in the form of Engineering services & EPC solutions in the selected process industries.
• Suggest solutions for enhancement of operational efficiency.
• Offers Technologies & systems which are :
• more INCLUSIVE in nature.
• Provide RIGHT & SUSTAINABLE solutions & enhance growth of our CUSTOMERS
Genesis:
Explore, Develop & Design green ways of protecting our
Surroundings, People and The Nature.
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Team…..
Promoted by Technocrats
Focus on “RIGHT ENGINEERING BASED SUPPLIES & SOLUTIONS”
Management team with clear vision & thoughts in place
Team members with HANDS ON experience in selected domains
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Fabrication works
Mechanical design &
fabrication conforming to
international standards
Fabrication of pressure vessels as
per ASME for U stamping.
Manufacturing facility at Pune
having area of 8000 feet² with
handling facilities for Stainless steel
and Carbon steel material.
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Our Evolvement from Inception…
2011 Establishment
2012 • First Contract for
45 KLPD
Distillation plant
2014
2013
2015
2013 • 1st Distillation plant
commissioned
• 2 Overseas contracts
• Dryer orders for
Starch Industry
• 45 KLPD Grain based
distillery order
2014 • Canada Re-distillation plant
commissioned
• First Integrated Evaporator order
• First DDGS Dryer Order
• Commissioning of Starch, Fiber &
Gluten Dryers
2015 • 1st Steam less Integrated
Evaporation
• 1st DDGS Dryer
• 170 KLPD Grain plant
under execution
• 90 KLPD up gradation &
capacity enhancement
2015
2016
2016 • Commissioning of 2nd
Steam less Integrated
Evaporation
• Second DDGS Dryer
shall be operating
• Integrated & Non
Integrated BSW
Evaporation plants shall
be operational
Commissioning of
2012
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Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Industry focus
Sectors Served:
• Ethanol from various raw materials
such as Molasses, Grains, Cane Juice
etc. for producing:
– Rectified Spirit
– Extra Neutral Alcohol
– Absolute Alcohol
• Starch & derivatives plant for
producing various base & modified
starches
• Standalone Evaporation & Drying
systems for Ethanol, Starches,
Chemical & Pharma Industries
• Zero Liquid discharge systems for
various process industries
Offerings :
• Engineering Services:
– Basic
– Detailed
– Procurement
– Project Management
• Lump sum Turnkey packages :
– Complete plants
– Process units
– Battery limit plants
• Studies & Audits of existing plants for
– improving efficiencies &
debottlenecking
8
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Scenario in General : Present & Likely future
PRESENT FUTURE
• Single plant up to 300 KLPD
• Reasonably low energy
consumption
• Sustainably reduced water
consumption
• Recovery of maximum by
products
• Relatively low pollution &
Damage to environment
• Proven Effluent treatment
packages for Grain & Molasses
distilleries
• Further enhanced capacities
• Refining & Purification of Co-
products & waste generated
from plant
• Maximization of value
through Value Added
Products
• Integrated Schemes &
Models with focus on ZERO
LIQUID DISCHARGE with
minimum energy
consumption.
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Energy & water Scenario : Present & Likely future
PRESENT FUTURE
• Overall steam consumption in
grain plants 4.5 Kg/lit – 5.0
Kg/lit
• Unused waste energy
• 9-10 Lit/Lit fresh water
consumption
• Substantial Cooling water
requirement
• Steam consumption @ 4.0
kg/lit
• Waste / Recycle stream will
have same temperature as
input temperature
• Minimum cooling water
requirement
• Lowest possible Fresh Water ;
Consumption Limited to
Atmospheric losses only
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
General Concerns…….
• Lower Recoveries
• Higher steam consumption
• Inferior Product quality
• Higher Impure Spirit Cut
• Non utilization of 100 % syrup
• Evaporation of spent wash to the RIGHT SOLIDS
• Working of Spent wash incinerator
• Quality of DDGS
• How to approach ZERO LIQUID DISCHARGE?
• Process Streams
• Non Process streams
• Steam & Power Balance
TECHNICAL:
• Right Project Investments
• Ideal Operating Costs
• Commercial Viability of expansions
FINANCIAL:
• Skill sets of Team
• Operational philosophy
• Right mix between Manual Operations Vs Automation
OPERATIONAL
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Challenges…..
Grain Based Plants
• Further reduction in energy consumption
• Evaporation of entire quantity of thin slops without steam
• No recycle of Thin slops in the Liquefaction
• Maintaining higher solids in thick slops
• Use of 100% Syrup in Drying process
• Use of Dryer vapours for energy optimization
Molasses Based Plants
Effluent treatment:
• BSW / RSW / RO Reject Evaporation
• Reduction in steam & energy
• Recycle of waste streams
Investment:
• Which route : EPC/EPCM/ Turn Key Contract ?
• In house Project Management or out sourced ?
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Two different types of Feed
Wet cake + Thick Slurry
Variation in feed specifications
• Inlet solids
• Different grains as feed to Distillery
• Stable unit operations (Decantation & Evaporation)
Large amount of mass
Higher Steam Consumption
Capability to handle Syrup
Higher product temperature
Higher Back Mixing
Maintaining Nutritional value of DDGS
Maintaining DDGS Color & Fragrance
Challenges in Drying @ DDGS
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DDGS Drying : Case Study
Higher starch Grains : Rice Lower Starch Grain : Corn, Bajara
• Plant Capacity : 100 KLPD Total Spirit
• Starch content : 68 %
• Alcohol concentration in FW : 14%
• Thick slop Generation : ~ 496 m3/Day
• Wet Cake Generation : ~ 100 Ton/Day
• Thin Slop Generation : ~ 396 m3/Day
• Solids in thin Slop : ~ 3.5 %
• Solids in Syrup : 35 % max.
• Qty. of DWGS : ~ 139.6 Ton / Day
• Plant Capacity : 100 KLPD Total Spirit
• Starch content : 60 %
• Alcohol concentration in FW : 13 %
• Thick slop Generation : ~ 549 m3/Day
• Wet Cake Generation : ~ 149 Ton/Day
• Thin Slop Generation : ~ 400 m3/Day
• Solids in thin Slop : ~ 6.5 %
• Solids in Syrup : 35 % max.
• Qty. of DWGS : ~ 223 Ton/Day
62% Increase in DDGS Dryer Capacity ???
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What does it mean…
Dryer for which material?
• Usage pattern of RM on yearly basis
• Influencing Grain
• Uniform mix of usage
• Heavy use of one type of Grain on yearly basis
• Selection Criteria:
• Technical Requirement
• Investment Vs Returns
• keep option of DWGS !!!
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Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
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Summarized Solutions ……
GRAIN MODULE:
• Low energy cooking process
• Minimal Cooling water recirculation rates
• Fermenters without Agitators
• Evaporation systems to handle entire Thin slops generated
• Maximum Evaporation through use of Alcohol vapours of distillation- Steam less Evaporation
• Systems to utilize 1:1 wet cake and syrup for Drying
• Lower energy requirement in the Drying systems
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Summarized Solutions ……
MOLASSES MODULE:
• Forced circulation Reboilers for reduction in the spent wash quantity at the generation stage.
• Lower steam consumption models in distillation
• Integrated Evaporation Models with minimum add on energy for concentration of :
• RSW
• BSW
• RO Reject
• Maximum Evaporation through use of Alcohol vapours of distillation
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Differentiators…….
Parameter General Trend VAPCO
Liquefaction system 0.60 Kg/lit with Cooling
water requirement
0.30 Kg/lit with minimal
Cooling water req.
Distillation Plant –Wash to
ENA with Integrated
Evaporation-Thin Slops
3.0 Kg / Lit of Total Spirit
with add on steam in FC
2.50 -2.70 Kg / Lit of TS
for Grain with NIL steam
for Thin Slop Evaporation
Distillation Plant –Wash to
ENA with Integrated
Evaporation-BSW
No running reference Expected 3.2- 3.3 Kg / Lit
of Total Spirit for BSW up
to 30% w/w solids
( Plant under execution)
Net water Evaporation
through Alcohol Vapours
3.0 – 3.25 Lit of water /
Lit of Alcohol
Max 5.0 Lit of water / Lit
of Alcohol
Thin Slop Recycle 15 – 35 % Zero Recycle
DDGS Dryer Rotary Dryer Multiple Options
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
OPERATING MODEL…..
Critical Sections Non Critical / Bought out Sections
- Basic & Detailed Engineering
- Propriety Items
- Erection Services
- Commissioning Services
(Liquefaction, Distillation, Evaporation, Dryers)
- Basic Engineering
- Detailed Engineering
- Supervision of Erection & Commissioning Services
( Milling, Silos, Fermentation, Storage, Utilities)
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BENEFITS….
Profitability & sustainability
Sustainable Financial cost
Optimized Project Investment
Process configuration with solution based approach rather than HARDWARE CENTRIC
Value engineering
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Value based Schemes READY for Implementation …
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Value Proposition
• Plants based on International Standards
• Flexible approach
• Environment Friendly and sustainable Plants with:
– Better product quality
– Optimized Product Yields
– Lower utilities & Operating Costs
– Compact Size
Results in Sustainability & attractive paybacks
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
INTRODUCTION
FOCUS
DISTILLERY SCENARIO
CHALLENGES
SOLUTIONS
OPERATING MODEL
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
THANK YOU